FRONT OIL SEAL REPLACEMENT [MZR 1.8, MZR 2.0, MZR 2.5]

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1.  Disconnect the negative battery cable.

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

3.  Disconnect the wiring harness.

4.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

5.  Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

6.  Disconnect the ventilation hose from the cylinder head cover.

7.  Remove the dipstick.

8.  Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

9.  Remove the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION).)

10.  Set the front mudguard (RH) out of the way. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

11.  Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

12.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

13.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

14.  Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (ATX) (See DRIVE SHAFT REMOVAL/INSTALLATION.)

15.  Remove in the order indicated in the table.

16.  Install in the reverse order of removal.

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1
Crankshaft pulley lock bolt
(See Crankshaft Pulley Lock Bolt Removal Note.)
(See Crankshaft Pulley Lock Bolt Installation Note.)
2
Crankshaft pulley
3
Front oil seal
(See Front Oil Seal Removal Note.)
(See Front Oil Seal Installation Note.)


Crankshaft Pulley Lock Bolt Removal Note

1.  Remove the cylinder block lower blind plug.

2.  Install the SST.

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3.  Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder top dead center (TDC) position (until the counterweight is attached to the SST).

4.  Hold the crankshaft pulley using the SSTs.

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Front Oil Seal Removal Note

1.  Cut the oil seal lip using a utility knife.

2.  Remove the oil seal using a screwdriver wrapped with a rag.

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Front Oil Seal Installation Note

1.  Apply clean engine oil to the oil seal lip.

2.  Push the oil seal slightly in by hand.

3.  Tap the oil seal in evenly using the SST and a hammer.

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Front oil seal press-in amount
0—0.5 mm {0—0.019 in}


Crankshaft Pulley Lock Bolt Installation Note

1.  Install the SST on the camshaft as shown in the figure.

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2.  Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST.)

3.  To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0), fix the crankshaft pulley to the engine front cover.

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4.  Hold the crankshaft pulley using the SSTs.

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5.  Tighten the crankshaft pulley lock bolt in the order shown in the following two steps using the SST (49 D032 316).

Tightening torque
Step 1: 96—104 N·m {9.8—10 kgf·m, 71—76 ft·lbf}
Step 2: 87—93°

6.  Remove the M6 x 1.0 bolt.

7.  Remove the SST from the camshaft.

8.  Remove the SST from the cylinder block lower blind plug hole.

9.  Verify that the teeth of the crankshaft pulley pulse wheel and the detection area of the crankshaft position sensor are installed to the correct positions. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

10.  Rotate the crankshaft clockwise 2 turns until the TDC position.

•  If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

11.  Install the cylinder block lower blind plug.

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Tightening torque
18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}